White Paper:

The Benefits
of 8-Axis in 3D
Scanning and
Metrology

This research has been sponsored by FARO

WHITE PAPER: THE BENEFITS OF 8-AXIS IN 3D SCANNING AND METROLOGY

TABLE OF CONTENTS
INTRODUCTION 3

REACHING FOR THE 8TH AXIS 4

A BUILT-IN 8TH AXIS 6

THE ADVANTAGES OF AN 8TH AXIS 7

QUALITY CONTROL APPLICATIONS 8

REVERSE ENGINEERING APPLICATIONS 10

FRAGILE APPLICATIONS 11

CONCLUSION 13

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WHITE PAPER: THE BENEFITS OF 8-AXIS IN 3D SCANNING AND METROLOGY

INTRODUCTION

Thanks to rapid advances in manufacturing, our products are evolving. Working

behind the scenes in advanced manufacturing is the equipment necessary to
perform effective product design and quality control. For that, manufacturers
are increasingly dependent on 3D imaging and metrology, including
measuring and laser scanning arms.

Despite major progress in the development of coordinate measuring machines

(CMMs) and 3D scanners since their inception, in the last decade there have
only been incremental improvements in terms of how users interact with laser
scan arms. This is due to the fact that metrology and laser scanning arms have
been limited to six or seven axes.

The FARO 8-Axis

Design ScanArm
features an
integrated 8th
axis in the form
of a rotational
platform.
(Image courtesy
of FARO
Technologies.)

A new generation of arms is beginning to emerge that provide an 8th axis,

opening up an unprecedented level of speed, flexibility and ease-of-use. As
a result, 8-axis 3D scanning and metrology—a concept trademarked by 3D
scanning company FARO Technologies—can be deployed for a variety of
applications, including: performing accurate quality control with large objects
in aerospace, reverse engineering parts in the automotive space, and digitally
cataloguing delicate objects in a museum setting.

In this white paper, we examine 8-axis arms and other scanning technologies,
as well as the benefits that an 8th axis provides, before exploring how the
technology can be used in quality control and product design applications.

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WHITE PAPER: THE BENEFITS OF 8-AXIS IN 3D SCANNING AND METROLOGY

REACHING FOR THE 8TH AXIS

6- and 7-axis 3D scan arms have become ideal for their flexibility, mimicking
that of the human arm. Additionally, as Dr. Mostafa Abdel-Bary Ebrahim, a
professor at King Abdulaziz University, pointed out in his history of laser 3D
scanning technology, “Such arm CMMs are often used where their portability is
an advantage over traditional fixed bed CMMs.”

In a recent report on 3D scanning technology, engineering.com pointed out,

“The primary advantage of using a scan arm is that it can accommodate
both scanners and touch probes, enabling a variety of measurements to be
performed with a single instrument.”

As product designers increasingly turn to 3D scanners for such uses as

reverse engineering, some users have learned that, beyond the scanner itself,
something may be missing. While the world of quality control is used to having
large amounts of space in which to walk around and scan an object, product
design engineers are more often limited to cubicles and office spaces. This
makes moving an arm around an object difficult, without wreaking havoc on
the surrounding space, knocking down computer monitors or even damaging
the object itself.

To get over this obstacle, users have typically had to rely on makeshift solutions
using third-party hardware. 3D scanning consultant Nick Lievendag has relied
on several turntables for photogrammetry and depth scanning. For smaller
objects, Lievendag has used a $9.99 Lazy Susan meant for computer monitors,
which he spins by hand during scans, as well as a $139 automatic turntable
designed for 360-degree product photography. For large objects, promotional
display companies make automated turntables that range in the hundreds
to thousands of dollars. All of the above solutions require the application of
high contrast reference targets to the object so that the object itself can be
distinguished from the background within scan software.

Scan in a Box released an automated turntable for 3D scanning using

structured light. This makes it possible to automatically rotate smaller, lighter
objects in front of the scanner to capture a series of scans to create a 3D model
of the object. However, because the system is paired with Scan in a Box’s
fixed, structured light system, it lacks the ability to reach some portions of the
object or use a touch probe within the same software and workflow. Therefore,
users wanting to perform such measurements or scans would have to find a
workaround solution outside of the company’s software.

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WHITE PAPER: THE BENEFITS OF 8-AXIS IN 3D SCANNING AND METROLOGY

There are also low-cost 3D

scanners with turntables being
developed by small startups using
crowdfunding sites, however
these devices are designed mostly
for do-it-yourself enthusiasts
who do not need a high level of
accuracy. In other words, such
products are not effective enough
for such applications as quality
control or professional reverse
engineering.

Until recently, users needing

an 8th axis and specifically a
rotational component have had
to rely on these makeshift or low-
cost technologies, resulting in a
number of drawbacks. In some
Scan in a Box’s
structured light cases, the product is not built
3D scan solution. specifically with 3D scanning and
. (Images courtesy metrology in mind and, therefore,
of Scan in a Box.)
does not provide a seamless
workflow. In other cases, object size and weight may be an issue. In none of
the aforementioned solutions is a touch probe, necessary for extremely precise
measuring and scanning, integrated.

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WHITE PAPER: THE BENEFITS OF 8-AXIS IN 3D SCANNING AND METROLOGY

A BUILT-IN 8TH AXIS

FARO Technologies, an established manufacturer of metrology and 3D imaging

hardware and software, released its first 6-axis CMMs in 1993. The addition of a
7th axis occurred in 1997, shortly followed by the release of the company’s laser
line probe in 2001. To properly orient the laser line to a part required a rotation
around the wrist of the scanning arm. Over 15 years ago, this was the last major
update with regards to how users interact with scan arms.

So far, FARO is the only company to have developed a solution that includes
both a 3D imaging and metrology arm with a connected 8th axis, in the form of
a rotational platform—thus forming the basis for FARO’s trademark of the term
“8-axis”, with regards to 3D scanning. The 8th axis uses the same mechanical
encoders and cartridges as the joints within the arm, but it is connected by
cable to the main hardware. This makes it possible to measure where the part is
in space, mounted to the rotational platform.

“There’s no accuracy loss with the 8th axis. The 8th axis has very similar or the
same performance as the rest of the arm,” Orlando Perez, Chief Platform Owner
for FaroArms and ScanArms at FARO, explained. “You essentially have a remote
point of articulation that you can sit next to the arm. You can place your part on
top of it, rotate it around and position it however you need to capture it.”

The rotational plate and FARO’s software are designed in such a way that the
plate is recognized as a part of the larger system, so there’s no need to place
reference targets onto the plate. All that is necessary before scanning and
measuring is a very quick calibration that locates the 8th axis in relation to the
arm.

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WHITE PAPER: THE BENEFITS OF 8-AXIS IN 3D SCANNING AND METROLOGY

THE ADVANTAGES OF AN 8TH AXIS

Adding a rotational plate to the CMM architecture may not seem like a huge
leap in development, but it just may be to users. The most obvious advantages
of this setup are the speed, flexibility and ease-of-use that the 8th axis brings.

All of these benefits are tied together: because the part can be rotated in front
of the user, they no longer have to walk around the part or, worse, move the
part to get a better angle. This not only reduces the overall scan time, but also
improves the ergonomics for the user, who is no longer burdened by reaching
awkwardly around the object. This makes it possible to scan an object up to 40
percent faster than with a 7-axis arm system.

When it comes to post-processing, there are then fewer scans that need to be
aligned due to the fact that new scan sessions are not required as frequently.
“Every time you move the arm or the part, you are required to do a series of
realignment measurements,” Perez said. “It takes a few steps to do that. By
introducing this additional axis to the arm, you completely eliminate those
steps.”

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WHITE PAPER: THE BENEFITS OF 8-AXIS IN 3D SCANNING AND METROLOGY

QUALITY CONTROL APPLICATIONS

Multiple market research firms have determined that 3D scanning has become
critical to quality control operations in manufacturing, indicating that this
segment is only growing as 3D scanning technology improves.

Market research firm ReportLinker lists quality control and inspection as the
most widely used application of 3D scanning in 2016, with the automotive
industry listed as the largest user: “The optical 3D scanning technology is widely
used in the automotive industry for quality control and inspection applications
to ensure that the components manufactured are within specified tolerance
levels. Optical 3D scanners are fast and flexible and have proven to meet strict
automotive production requirements. For instance, in body-in-white (BIW)
assembly, 3D scanners precisely measure and monitor the locations of slots,
studs, holes, and other features to ensure conformity to strict automotive
tolerance.”

The introduction of an 8th axis to the world of 3D imaging and metrology

opens up new applications that were previously difficult to pursue with older
generations of scanning arms. These include scanning and measuring large-
scale objects.

A large scale
model of a train
hangs over the
rotational plate
of the 8-axis scan
arm, while the
operator rotates
the object to
capture from all
sides.
(Image courtesy
of FARO
Technologies.)

Parts that may have been difficult to manage due to their large size or heavy
weight can be dealt with much more easily using a rotational 8th axis platform.
For instance, items that may be long and hang over the plate can be easily
scanned from all sides and even beneath by moving the scan arm below
the overhang area. This is particularly useful for weightier items that may be
onerous to move around for multiple scan sessions.

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WHITE PAPER: THE BENEFITS OF 8-AXIS IN 3D SCANNING AND METROLOGY

Examples of items that might fit into this category are such bulky objects as
steel engine blocks or car doors, in the automotive space. Neither petite nor
easy to move, these parts could benefit from an 8th arm assist so that users can
gently rotate the items as they perform their scans and measurements without
performing tedious rearrangements of the parts to capture every angle.

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WHITE PAPER: THE BENEFITS OF 8-AXIS IN 3D SCANNING AND METROLOGY

REVERSE ENGINEERING APPLICATIONS

Beyond quality control, the technology is increasingly used for reverse

engineering, as well. MarketsandMarkets wrote: “The 3D metrology market for
reverse engineering is expected to grow at a high rate between 2017 and 2023.
Industries such as automotive, aerospace & defense, and manufacturing have
started using 3D metrology for design modification of actual objects to produce
customized cars, spare parts, and produce parts whose production had been
discontinued. High precision, faster product analysis, and the ability to make
changes in the original product are the major drivers of 3D metrology market
for reverse engineering.”

One potential vertical in which such a technology would be relevant is in the

automotive aftermarket space. If an aftermarket part manufacturer wants
to create a custom door handle for an out-of-production car, it’s possible to
actually affix the original door to the rotational plate and scan the assembly.
Using the laser line probe, it’s possible to capture the imperfect 3D data
associated with molded parts and, with a hard probe, contact can be made
with precision machined components to ensure the highest possible accuracy.

According to management consulting firm McKinsey & Company, the

automotive aftermarket space is quickly evolving, in part driven by new digital
technologies. “Digital-related revenues will triple to a share in sales of almost
20%,” a 2017 report explains. The report goes on to say, “80% of players say they
are currently not well prepared – mainly due to a lack of strategic focus and
skills and insufficient digitization resources.”

While the report places an oversized emphasis on the Internet-of-Things, the

world of 3D printing has created unique possibilities for reverse engineering
and aftermarket applications. By 3D scanning a part, it’s possible to obtain a 3D
model that can then be modified for 3D printing. For instance, using topology
optimization, the component can be designed in a way that significantly
reduces weight, while maintaining or sometimes increasing overall strength.
Additionally, personalized details can be added, such as a customer’s name, to
create added value.

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WHITE PAPER: THE BENEFITS OF 8-AXIS IN 3D SCANNING AND METROLOGY

FRAGILE APPLICATIONS

While it is a practice being increasingly employed by a number of institutions

globally, the Smithsonian Institution may be the most well-known user of
3D scanning for the purpose of artifact preservation, public interaction and
education. Through the Smithsonian’s Digitization Program Office, the
organization uses a variety of 3D scanning technologies to capture models of
objects from its 19 museums and libraries.

3D scanning enables the Smithsonian to create a digital historical record of

the works contained within those facilities. Had the National Museum of Brazil
been able to begin such a process, some of the museum’s 200-year-old artifacts
could have potentially been saved after the facility experienced its recent
devastating fire.

The Digitization
Office at the
Smithsonian
Institution
3D scanning
sculptures from
antiquity.
(Image
courtesy of the
Smithsonian
Institution.)

In a paper dedicated to the topic, the senior conservator at the Smithsonian’s

Museum Conservation Institute, Melvin Wachowiak, and one of the museum’s
3D scanning specialists, Basiliki Vicky Karas, detailed a number of the uses 3D
scanning serves in the museum’s operations:

“3D scanning systems are relatively new, highly precise measurement tools.
These systems provide a high quality, high-resolution 3D archive of an object’s
surface topography with measurement accuracy to the sub-millimeter level.
In addition, 3D scanning allows measurement of the surface geometry, texture
(which, in the jargon of 3D surface imaging, includes color), and volume of
most objects, without contacting an object’s surface. As in two-dimensional
photography, a graphic representation of the surface is created. The 3D data

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WHITE PAPER: THE BENEFITS OF 8-AXIS IN 3D SCANNING AND METROLOGY

provide an extremely accurate record of an object’s physical structure, unlike

flat photographic representations of objects or virtual reality displays of objects
created by compiling 2D photographic images.”

The first major application listed by the conservators is for “virtual examination
and research,” with the authors explaining, “The objects can be brought into
the virtual workroom, and there is essentially no impact on the object’s physical
integrity.” They go on to describe how 3D scanning affected research on a
sculpture by Matisse: “For this research, several bronze, plaster, and terra cotta
pieces were fully scanned and virtually compared. In the past, calipers and other
tools would have been used to carry out this kind of analysis. The opportunities
for creating multiple cross sections and 3D overlay of data would not have been
possible without 3D scanning.”

Aside from virtual examination, the conservators note the ability to restore
artifacts by 3D scanning an object, designing missing portions in CAD and then
3D printing the replacement pieces. Since Wachowiak and Kara have written
the paper, more applications have been introduced by the Smithsonian. 3D
scanning has made it possible for the public and educational institutions to
access the works both online, in the form of 3D models, and at home, through
the use of 3D printing. The Smithsonian has given the public the ability to 3D
print select objects that have so far been captured with 3D scanning.

The organization has been using a FARO Design ScanArm to perform much
of its cataloguing work. With the introduction of 8-axis 3D scanning, the
organization has one more tool in its toolbox that can either be utilized with
large or very delicate items. These items necessitate the minimum amount of
movement possible, in order to refrain from making even slight modifications
to the parts’ geometries.

“Object handling is actually the most critical part of the digitization process,”
said Vincent Rossi, Senior 3D Program Officer for the Digitization Program
Office at the Smithsonian Institution. “If you mishandle an object, like Neil
Armstrong’s glove, it’s one of a kind. If something were to happen to the object,
that would be a tragedy. So, any scanning solution that minimizes object
handling is beneficial.”

As the Smithsonian Institution aims for its moonshot goal of scanning a larger
percentage of the 155 million objects in its collection, efficiency is key, according
to Rossi. “The majority of the labor in creating a 3D asset is in the post-
processing. Streamlining the post-processing is critical. With the 8-axis, I expect
that it’s going to help us reduce the need to move the object around and
register new scans because the turntable is moving,” Rossi explained. “Anything
that speeds up capture and minimizes post-processing is what we think about
every day. If we’re doubling our ability to scan from 10 to 20 objects a day, that’s
a big deal for us. It’s essentially like doubling our team.”

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WHITE PAPER: THE BENEFITS OF 8-AXIS IN 3D SCANNING AND METROLOGY

CONCLUSION

The 3D scanning industry has demonstrated continual evolution, a fact backed

up not just by market research but by the introduction of new products to
the marketplace. The latest advance made to scan arm hardware itself is the
addition of an 8th axis, which advances how users interact with scan arms
altogether. The incorporation of a rotational plate into scan arm hardware not
only means more comfort for the user, but faster scanning and post-processing,
as well as extended capabilities with regards to large and delicate objects.

THIS RESEARCH HAS BEEN SPONSORED BY FARO

To see the DSA2.5C FARO Design ScanArm and
8-Axis in action, visit https://www.faro.com/products/
product-design/faro-design-scanarm/

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